SEAT Workshop Service and Repair Manuals

Removing and installing turbocharger Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter. Special tools and workshop equipment required

t  Wrench kit 17 mm -T10395-, see equivalent → Anchor

t  Retainer (transport lock) -T10403- t  Torque wrench -VAG 1331-, see equivalent → Anchor.   Caution If the turbocharger has suffered mechanical damage (e.g. damaged compressor wheel), it is not sufficient merely to fit a new turbocharger. To avoid subsequent damage, the following work must be carried out: t  Check air filter housing, air filter element and intake hoses for soiling. t  Check the whole charge air path and charge air cooler for foreign objects. If foreign matter is found in the charge air system, clean all relevant ducts and hoses and renew the charge air cooler if necessary. Observe safety precautions → Chapter. Observe rules for cleanliness → Chapter. »Carry out the following work sequence« Removal: –  With ignition switched off, disconnect battery earth strap. → Electrical system; Rep. gr.27. –  Remove engine cover panel → Chapter.

–  Pull connector -1- off position sender for charge pressure positioner -G581- on turbocharger. –  Remove connection hose -2-. –  Pull off vacuum hose on turbocharger. –  Unscrew bolt -3- (attached) and screw intake hose clockwise out of and remove from its bracket. –  Remove air filter housing with air mass meter and connecting pipe → Chapter. –  Remove plenum chamber bulkhead → General body repairs; Rep. gr.50.

–  Release clip -1- from connecting hose to the impulse absorber. Unscrew securing bolts -arrows- from charge air pipe. –  Pull connecting hose off turbocharger as far as possible.

–  Unscrew bolts -arrows- and remove pulsation damper -2-.   Note Disregard: -Pos. 1-. Loosen particulate filter.

–  Disconnect the following connectors: t  -1-exhaust temperature sender 1 -G235- connector t  -2-exhaust temperature sender 3 -G495- connector t  -3-exhaust temperature sender 4 -G648- connector t  -4-Lambda probe -G39- connector

–  Unplug electrical connector -3-. –  Unscrew screws-2-, remove the differential pressure sender -G505- and loosen the hoses -1-. –  Pull lines out of retainers on engine and remove heat shield from particulate filter; if necessary remove cable ties.

–  Unscrew the bolt -1- from the centre support of the particle filter mount. –  Remove securing clamp -2- between particulate filter and turbocharger.

–  Unplug electrical connector -3-. –  Unscrew screws-2-, remove the differential pressure sender -G505- and loosen the hoses -1-.

–  Remove connecting pipes -A-.   Note The flexible joint in the front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.

–  Fix the transport lock -T10403--arrow- on the decoupling element in the front exhaust pipe.

–  Unscrew bolts -1- and then nuts -2-.

–  Pull the particulate filter from its brackets in the mountings -arrows-.

–  Slacken the fastening nuts -arrows- of the clamping sleeve and then lower the exhaust pipe to the rear.

–  Remove the particulate filter -1- and fix accordingly on the steering box -2- in order not to damage it.

–  Unscrew bolts and remove pipes -A- for exhaust gas recirculation. Catch leaking oil used oil collection and extraction unit -V.A.G 1782-.

Threaded connection -2- must not be loosened. –  In order to unscrew the union nut -3-, counterhold the threaded connection -2-. –  Unscrew the bolts -1, 4 and 5- and the banjo bolts -6, 7-. –  Remove turbocharger support and oil supply line.   Caution Exhaust temperature sender 1 -G235- conceals upper threaded connection of turbocharger support. It must not be bent. Due to this it must be removed.

–  Remove exhaust gas temperature sender 1 -G235--1-.

–  Unscrew bolts -arrows- and remove heat shield.

–  Unscrew nuts -arrows- and pull turbocharger with exhaust manifold off cylinder head.

–  Carefully remove turbocharger from above in direction of gearbox. Installation   Caution Before installing, check whether decoupling element of oil return line is bent and thus stretched. In this case, hair-line cracks may be caused here that could lead to oil leaking. When necessary, replace the oil return line before fitting the turbocharger. –  Installation is in the reverse sequence of removal. Note the following: t  Note installation position of exhaust temperature sender 1 -G235-.

Installation position of exhaust gas temperature sender with angled cable guide   Note When the exhaust gas temperature sender with angled cable guide is being removed, the distance -a- of 3 ... 5 mm to screw support against turbocharger. Tightening torques: Turbocharger → Chapter Tightening torques: Remove oil supply line and oil return line (turbocharger support) → Chapter

–  Observe sequence when installing particulate filter:

1.	Position particulate filter on turbocharger and secure clip -1- loosely
2.	Screw in nuts -2, 4- and bolts -3, 5- loosely by hand l  Particulate filter and retainer must be able to move
3.	Tighten clip -1-
4.	Tighten nuts -2, 4-
5.	Tighten bolts -3, 5-